Forklift Battery Regeneration

Battery Regeneration is a service provided using a highly specialised Charger in order to recover a Batteries lost capacity and life cycles. It is important to note that each Lead Acid Battery has an estimated cycle life of 1500 charge and discharge cycles over the course of its lifespan. If 5 cycles are used weekly, the estimated life expectancy of the Battery pack is 5 Years, 2.5 cycles used weekly then this extends out to a 10 year life expectancy etc. The overall life of a high quality Flooded Lead Acid Forklift Battery is 6-8 Years across all application usages on average, we have seen Batteries needing replacement at less than 3 Years of age due to excessive usage and charging and lack of required maintenance, but also last for over 20 Years if used in a low use application, with the product maintained and looked after accordingly

Misuse of Batteries results in sulphation build up occurring on the internal positive and negative plates, effectively blocking the chemical reaction required to provide Battery power output capacity. The Regeneration process reverses this sulphation build up process, returning the Battery back to a usable state by liquifying the hardened sulphation build up on the plates through a very specific applied charge algorithm.

Lost usage cycles where the Battery is testing poorly and falls within the confines of potential Regeneration are almost always the result of the following:

Each Battery is inspected, with the determining factors for this service relative to the age of the Battery asset and condition of the Battery, prior to making an informed decision. IBA do not charge our clients for Batteries that are found to not be recoverable, as the only other option if this process does not work is to replace the Battery pack.

A successful Battery Regeneration is supplied with a 1 Year Full Replacement Battery Warranty applied to the product, with this service obviously significantly cheaper than a Battery pack replacement. A validated result is acquired by achieving 75% of a Batteries Nominal Capacity, noting that new Batteries usually come with a +90% Capacity rating upon supply, due to required Australian Import requirements for all Industrial Motive Power suppliers (shipping times usually range from 6-10 weeks post production and formation charge), eventually reaching 100% capacity after a number of Charge and Discharge cycles are facilitated, with this percentage slowly dissipating over time and usage as the internal plates break down during their standardised life usage practices.

It is important to note, this is not a miracle process for Batteries, once a Battery has reached the end of its service life (approximately 1500-1800 cycles) internal cell breakdown occurs that can not in any way be reversed, and the Battery will require replacement at the end if its expected cycle life as would be expected.